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Old 01-27-2012, 07:13 PM   #4831
ben2go
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Location: Upstate SC USA
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Quote:
Originally Posted by Rasthomas View Post
Not sure, I never ride this bike at night. It is my trail bike.
Then no worries mate.
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Old 01-28-2012, 05:08 PM   #4832
daffodil60
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Location: Vancouver Island
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Clutch Lever Replacement

Hi everyone, I am fairly new to riding and definetly havent done any mechanics before. I have a 2010 DR200. I love my bike and as every newbie does, I placed my bike on the ground a little suddenly and unexpectedly when I stopped on uneven ground.... So consequently I broke the end off my clutch lever. I have the replacement now and want to know if someone could give me step by step instructions on how to do the replacement. Even better if someone has pictures or can scan the instructions for me.
Thanks

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Old 01-28-2012, 05:28 PM   #4833
Highaltidude
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Quote:
Originally Posted by daffodil60 View Post
if someone could give me step by step instructions on how to do the replacement.
Easy job..... Take the nut off the bottom of the bolt, pull the bolt out the top. Now pull the lever away from the mount (cable still attached). You'll have to rotate the handle about 90 degrees clockwise so the cable lines up w the slot in the bottom of the lever. Now you can pull the lever "up" and off the cable.

When you put it back together, over tightening the nut can cause the lever to bind in the mount.

Chuck
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Old 01-28-2012, 09:39 PM   #4834
ben2go
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Quote:
Originally Posted by daffodil60 View Post
Hi everyone, I am fairly new to riding and definetly havent done any mechanics before. I have a 2010 DR200. I love my bike and as every newbie does, I placed my bike on the ground a little suddenly and unexpectedly when I stopped on uneven ground.... So consequently I broke the end off my clutch lever. I have the replacement now and want to know if someone could give me step by step instructions on how to do the replacement. Even better if someone has pictures or can scan the instructions for me.
Thanks

Attachment 312443
Please purchase a service manual.It is worth it.

This should be the same for 2010 models as well.
Suzuki Factory Service Manual / 1996-2009 DR200SE / Pt # 99500-41141-03E
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Old 01-29-2012, 02:15 PM   #4835
Andyinhilo
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Location: Hilo, Hawaii
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Quote:
Originally Posted by Highaltidude View Post
Easy job..... Take the nut off the bottom of the bolt, pull the bolt out the top. Now pull the lever away from the mount (cable still attached). You'll have to rotate the handle about 90 degrees clockwise so the cable lines up w the slot in the bottom of the lever. Now you can pull the lever "up" and off the cable.

When you put it back together, over tightening the nut can cause the lever to bind in the mount.

Chuck
You need to remove the clutch switch on the bottom of the perch before removing the lever, so it does not get broken. Re-install it last.
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Old 01-29-2012, 02:31 PM   #4836
godwinmt
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I've replaced the clutch lever numerous times and have never removed the clutch switch in the process. As long as you rotate the lever back in you're just fine.
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Old 01-29-2012, 03:00 PM   #4837
Klay
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If you remove the clutch switch, take care not to lose the little spring. It'll spring out and hide.
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Old 01-29-2012, 05:39 PM   #4838
thesurvivalist
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Brake Shoes

My bike has complete nearly 5k and the rear brakes are getting very soft. Are they supposed to be adjusted from the outside or do they just need replacing? Also does, the rear wheel need to be removed to changed the brake shoes?
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Old 01-29-2012, 06:39 PM   #4839
Klay
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Originally Posted by thesurvivalist View Post
My bike has complete nearly 5k and the rear brakes are getting very soft. Are they supposed to be adjusted from the outside or do they just need replacing? Also does, the rear wheel need to be removed to changed the brake shoes?
You adjust the brake shoes via the nut on the end of the brake rod. Just tighten it down. It's that simple. Yes, you have to take the wheel off to get at the brake shoes. They're unlikely to have significant wear...they last a very long time on the DR200.
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Old 01-29-2012, 07:29 PM   #4840
thesurvivalist
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Cheers again mate.
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Old 01-30-2012, 12:05 PM   #4841
daffodil60
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Location: Vancouver Island
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Quote:
Originally Posted by Highaltidude View Post
Easy job..... Take the nut off the bottom of the bolt, pull the bolt out the top. Now pull the lever away from the mount (cable still attached). You'll have to rotate the handle about 90 degrees clockwise so the cable lines up w the slot in the bottom of the lever. Now you can pull the lever "up" and off the cable.

When you put it back together, over tightening the nut can cause the lever to bind in the mount.

Chuck
Thanks Chuck I will try this.
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Old 01-30-2012, 02:47 PM   #4842
striperjunky
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Joined: May 2008
Location: Fairbanks, Ak.
Oddometer: 151
spare fuel pack

I just finished up fabricating a spare fuel pack bracket for little suzi, here's some pix. Let me know what you guys think? Were planning another trip to the UP this spring and wanted the added security of extra fuel. for those who want more pix, email me and i will send you the full load. Sorry the pix are kind of big!

Rocky




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Old 01-30-2012, 02:49 PM   #4843
Klay
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What kind of bash plate is that?
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Old 01-30-2012, 02:55 PM   #4844
striperjunky
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bash plate

That would be a Ricochet brand plate (brand sticker is in the last pic) and i think it ran around $80.
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Old 01-30-2012, 02:56 PM   #4845
Klay
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Thanks
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